Tri-walk K.k.

Tri-wall K.k.

Kunio Cho

Yutaka Sato

Mitsutoshi Ogata

A method for producing an interior a product comprising a corrugated cardboard base formed into a predetermined shape and a decorative skin layer laminated to one side of the cardboard base. Using a hot-press, a substantially planar cardboard base comprising a corrugated core and liners laminated to both sides of the core through thermoplastic resin films is formed into a predetermined shape by heat and pressure at a temperature high enough for remaining heat to be sufficient to melt a hot melt adhesive on the surface of the cardboard base after removal of the formed cardboard base from the hot press but not so hot as to scorch the paper of the cardboard base. The formed cardboard base is then taken out of the hot press and transferred into a cold press, thereafter a decorative skin is put on the surface of the formed cardboard base through a hot melt adhesive. The formed cardboard base and the skin layer are pressed in the cold press, allowing the adhesive to be melted by the remaining heat of the cardboard base to bond the skin layer to the formed cardboard base. While the skin layer bonds to the cardboard base, the thermoplastic resin interposed between the core of the cardboard base and each liner solidifies to fix the formed shape so as to prevent spring-back. The interior trim product can be used for the ceiling of an automobile.

Forming method for interior trim material made of corrugated cardboard

Corrugated cardboard is molded into a desired shape for use in interior trim, such as for use in lining the ceiling of an automobile. The molded corrugated cardboard is obtained by applying a hot-melt adhesive onto all or at least a portion of a side of a base layer of, for example, resin felt or non-woven fabric. The base layer is then applied to a plate-like corrugated cardboard layer such that the hot melt adhesive is between the two layers. The corrugated cardboard and base layers are then molded together. The base layer may be put on only a portion of the cardboard layer where molding is apt to cause wrinkling or rupture of the cardboard layer, or the base layer may be applied to an entire surface of the corrugated cardboard layer. Even if the corrugated cardboard wrinkles or ruptures during molding, the wrinkle or rupture is filled by lofting of the base layer which is simultaneously molded in a superimposed state on the corrugated cardboard. Thus, when a decorative skin layer is laminated to the surface of the molded article, any wrinkles or ruptures which were generated during the molding process do not appear on the surface of the finished product.

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Tokyo, Japan

Kunio Cho